Air Box Mod

At the Krazy Horse bash yesterday was Roger from Rutland, he on this forum but can’t remember his handle/ call sign / user id, & he has rather cunningly & neatly done this to his box, the molded round raised lip is apparently taken from the air inlet of the Morgan sports car,inside is a “ K & N “, Roger said he was either going to upgrade to VIP on try work out how to load more pic,s .
Rogers bike Has a bit of Rev hang as he calls it ,his next move are linking out the lambda sensors & hooking up a power commander.

Thanks.
Nice pics.
Is Roger's bike a single or dual seat?

Single seat silver sport to be precise,parked up to a new one

I'm interested in his project.
However, placement of a PC on a single seat Commando is a problem.
The dual seat model has a nice, suitably sized niche directly below the cushion.
I can't find a space for it under the seat or the tank on my single/solo seat model.

What ? Won't Fit ?


Finally got the power commander v installed

WOW, What a difference, totally different bike to ride .

Great at low rpm around town slow speeds.

Great at high rpm on open roads.

Not looking for amazing HP just a nice stable running engine .

Looking forward to getting out and riding the Norton now

Power Commander V p/n 12-009

$800 AUS Installed and tuned.

Best money spent on bike so far .


Opened up the air intake to 90 mm



Dyno tune

Fits nicely behind air box intake

Tony,
Those pics are from Paul (pingu-nz) on his dual seat model 961.
Fits beautifully under seat cushion of dual seat version.
On a solo seat model the plastic tail section base covers the area under the cushion.
Cushion leaves zero space between it and plastic tail base.

Hosted on Fotki

BLIGHTYBRIT/SF said:

View attachment 4702 View attachment 4703 View attachment 4704 At the Krazy Horse bash yesterday was Roger from Rutland, he on this forum but can’t remember his handle/ call sign / user id, & he has rather cunningly & neatly done this to his box, the molded round raised lip is apparently taken from the air inlet of the Morgan sports car,inside is a “ K & N “, Roger said he was either going to upgrade to VIP on try work out how to load more pic,s .
Rogers bike Has a bit of Rev hang as he calls it ,his next move are linking out the lambda sensors & hooking up a power commander.

Click to expand...

Hi,

I've just upgraded to VIP member so should be able to add some more photos of the modification shortly.

Cut a cigarette pack size square hole in the seat pan then. Your bum wont feel it. Or put it further back ?

I’d be tempted to cut a hole in the base too, can’t see any issue with that.

Also, the Shorai battery is quite a bit less tall that the stock job. I suspect that the PC box would fit either underneath, or on top of, a Shorai battery.

Attached are some photos of the air box modifications that I've done on my Commando.

Photo added.

I replaced the air filter with a K&N filter as the factory filter is rather brittle and I damaged the rim and the replacement filter I ordered from the factory is significantly shorter and therefore a lower area which would defeat the object of the exercise! The K&N filter is the same dimension as the old factory filter with one open end and one closed. I punched a second hole in the filter to allow air entry from both ends and to connect to the new air infeed. To seal the filter under the seat I purchase some "P" profile rubber strip.

Taking the bike out for the first time at the weekend, it did seem to pull harder at the top end. I will however try and get it on the dyno to see if it's made a measurable difference.

Is the K&N filter able to replace the stock filter without cutting the hole in the bottom ? Can you share what the K&N part number is ? Very good work ! I think that there will be a gain for your efforts. Did you use the top hole as a guide to get the bottom hole centered with a pilot ? I can imagine that this is a tricky part !

That is neat sir.
When I looked at your picture, I could imagine the airflow over the rear of the bike trying to suck air OUT through the filter at speed.
I’m thinking a baffle plate in the middle might be a good idea?

The K&N filter I used is shown on the attached spec sheet together with the inlet tube I had made to match the inlet trumpet.

The inlet trumpet came from Cain Poulton who has a business called Wolf Performance and he makes parts for Morgan Cars. He's a great chap and I'm sure would be happy to provide the trumpets (web site below).

https://www.wolfperformance.co.uk/valances.html

The underside of the air-box isn't flat so I positioned the trumpet centrally and as far towards the back as possible so as to be flush when installed. I then traced the outside of the trumpet onto the air-box and used a Dremel to relieve the air-box so that there were no gaps between the trumpet and air-box.

As the base isn't parallel with the top opening I used a local engineering firm who make exhausts to make me an angles inlet to allow a perpendicular entry into the filter (I hope this makes sense). See attached drawing.

As the K&N filter has a collar extending the original inlet hole, when this is pushed onto the new infeed, the blank end of the K&N sits flush with the top of the air-box. I did consider just leaving the top feed blank but as I'd made a tool for punching the new hole (tune with sharpened edge) I decided that two holes would be better than one... you can't have too much air!

Finally, with the air filter in position there was an qpprox. 2mm clearance all the way around. To fill this I bought a "P" profile strip and pushed the "I" part of the strip into the gap and this leaves an "O" around the top of the filter and this seals the filter against the Norton plastic top inlet.

I hope that you can follow this and I'll photograph the top of the filter in the next day or so.

Kin amazing , don’t go anywhere ,we need passionate imput like this

Finally a photo of the filter in place with the “P” strip in situ.

What are you thoughts having done this?

If should breath a heck of a lot better.

Any noticeable different to performance at all?

Fast Eddie said:

What are you thoughts having done this?

If should breath a heck of a lot better.

Any noticeable different to performance at all?

Click to expand...

I’m running the same map a when it was on the dyno so hopefully that will show an improvement. I do however feel it pulled harder on the run to/from Krazy Horse so I’m hoping there will be a measurable difference.

I have also disconnected the Lamda sensors this afternoon so I’ll take it for a spin tomorrow & see if that’s made more difference.